Sodi Sigma DD2 User Maintenance Manual Download Page 7 | Manualshive

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Sodi Sigma DD2 User Maintenance Manual Download Page 7

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DD2 MANUAL

SEQUENCE OF ASSEMBLY AND INSTRUCTIONS

STEERING COLUMN AND STEERING WHEEL (chapter 4).

FUEL TANK AND OVERFLOW BOTTLE (chapter 5).

SEAT (chapter 6).

KG UNICO BODYWORK (chapter 7).

SODI BODYWORK (chapter 8).

NOTE:

Recommended tightening torques:

Ø6 = 10 to 12 m.N

Ø8 = 12 to 24 m.N

Ø10 = 24 to 48 m.N

Do not overtighten screws and bolts

Screws without bolts are to be blocked with 1 drop of special glue (LU 861.001)

Lubricate rotating parts, ball joints, gas cable ….

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Summary of Contents for Sigma DD2

Page 1: ...USER MAINTENANCE GUIDE DD...

Page 2: ...OF THE SEAT 10 7 ASSEMBLY OF THE KG UNICO BODY WORK 12 8 STARTING YOUR DD2 15 STANDARD ADJUSTMENTS 9 TABLE OF THE STANDARD ADJUSTMENTS 16 10 ADJUSTMENT OF THE FRONT END 17 11 ADJUSTMENT OF THE REAR EN...

Page 3: ...tion This manual contains instructions for the assembly and the maintenance of your kart according to the rules of the art Safety on a track is a personal and collective matter at the same time taking...

Page 4: ...se get advice from the SODIKART distribution network The SODI DD2 is designed for safety and reliability in normal conditions of use Before using it please read this manual and carefully follow the in...

Page 5: ...RT FIXING KIT LOWER SPOILER SUPPORT FRAME DD2 SEAT KG UNICO SIDE POD LEFT SIDE POD SUPPORT STEERING COLUMN ASSY STEERING WHEEL SLOTTED NUT KEY STUB AXLE SPACER ADJUSTER STUB AXLE SCREW ADJUSTER NOTE P...

Page 6: ...OU 912 004 T handle socket spanner 10 mm OU 912 001 T handle socket spanner 11 mm OU 912 002 T handle socket spanner 13 mm OU 912 003 Key for slotted round nut M20 supplied OU 914 003 Stub axle space...

Page 7: ...TLE chapter 5 SEAT chapter 6 KG UNICO BODYWORK chapter 7 SODI BODYWORK chapter 8 NOTE Recommended tightening torques 6 10 to 12 m N 8 12 to 24 m N 10 24 to 48 m N Do not overtighten screws and bolts S...

Page 8: ...ing column support on the two pins canons 1 and 2 Put the CHC M6x30 3 screws nylstop M6 bolts as indicated in picture 2 Tighten 4 5 PIC 3 4 2 ASSEMBLY OF THE STEERING COLUMN PIC 3 Insert the threaded...

Page 9: ...ering wheel support 2 Tighten the steering wheel support on the steering column Check once the steering system is assembled please check that the steering wheel is free to make a quarter of a turn rig...

Page 10: ...umn support 1 and the steering column 2 see pictures Tighten with the fly nut 3 5 4 9 6 7 8 Insert the overflow bottle 4 between the nassau panel supports 5 Connect the overflow bottle hose 6 to the r...

Page 11: ...t of the seat recommended by SODIKART for the DD2 Get the seat supports 1 closer or wider depending on the seat size The washers of the seat fixing kit comply with CIK FIA and with your local national...

Page 12: ...REAR AXLE AND THE MIDDLE OF THE ROUND REAR EDGE OF THE SEAT 210mm Measure from the middle of the rounded edge 6 3 DISTANCE BETWEEN THE AXIS OF THE LEFT SIDE STUB AXLE FORK AND THE MIDDLE OF THE REAR...

Page 13: ...the CIK FIA rules carefully prepare the supports as indicated below Measurements in mm SPOILER LOWER SUPPORT SIDE POD SUPPORT DRILL 6 5MM DIAM HOLE VERTICAL DRILL 6 5 MM DIAM HOLE HORIZONTAL End to cu...

Page 14: ...ons for the other support 7 3 ASSEMBLY ON THE CHASSIS PIC 2 PIC 2 2 Insert the flexible plastic sleeves in the frame Insert the ends of the support in the sleeves Tighten with screws and bolts through...

Page 15: ...with the supplied bolts and screws Position the nassau panel on the connection part 8 Insert the screws Place the bolts and tighten 7 8 ASSEMBLY OF THE UPPER NASSAU PANEL PIC 7 Tilt the upper nassau p...

Page 16: ...d compulsory Gloves compulsory Neck protection CIK FIA approved compulsory Rib protection fitting pilot s size and seat recommended Rain suit with water tight fasteners recommended when necessary CHOO...

Page 17: ...RSION BAR REMOVE the double lateral craddle REMOVE the torsion bar PLACE the double lateral craddle PLACE the torsion bar horizontally 4mm 4mm 4mm 4mm 2mm 2mm 3 rings inside Short hub 60mm All rings i...

Page 18: ...3 rings inside with SHORT HUBS L60mm WET TRACK On wet track place all the rings inside with LONG HUBS L80mm For more grip forward add one or two 5 mm rings on the chassis side Steering becomes harder...

Page 19: ...ce one 4mm spacer on top and one 4 mm one 2 mm spacer at the bottom 1 4mm 1 DRY TRACK 4 2mm WET TRACK Place one 4 mm one 4 mm spacers on top and one 2 mm spacer at the bottom 2 The adjustment of dry t...

Page 20: ...or more eccentrics REDUCE THE CASTER fig 2 2 ou 3 eccentric even more in extreme conditions in low caster position diam 4 mm pin on the fork Marked slot 1 for 1 Eccentric HIGH CASTER LOW CASTER Eccen...

Page 21: ...s the outside of the chassis Eccentrics at the bottom The mark is positioned towards the inside of the chassis INCREASE THE CAMBER fig 4 Use the same position fig 4 and change the eccentric of 1 by th...

Page 22: ...on the right side 1 5mm bigger than the tie rod length on the left side 6 When A 2mm than B the front train is well adjusted Tighten the 2 lock nuts on each tie rod 2 7 Remove the adjustment tool 1 NO...

Page 23: ...DD2 MANUAL 10 5 ADJUSTMENT OF TIE RODS ADJUSTMENT B 3 1 2 3 A B ADJUSTMENT A 3 Lighter steering NOT RECOMMENDED IN WET CONDITIONS 1 2 3 A B 22...

Page 24: ...t the wheels mind the direction of rotation indicated on the side of the tires Tighten the bolts and block NOTE A rear tracking width is measured from the outside of the rims left and right A wider re...

Page 25: ...the kart AXLE DIAMETER 50 STANDARD MD 25 Available in the ITAKA catalogue AXLE DIAMETER 50 FLEXIBLE MD 20 Available in the ITAKA catalogue A flexible axle suits high grip conditions Heat and or gum o...

Page 26: ...he best position of the seat adapted to your size and weight by trial and error We recommend you to bear in mind the following SEAT MOVED FORWARD Gives more grip on the front wheels more sliding of th...

Page 27: ...tool 2 4 Put grease 3 Available on the ITAKA catalogue on the edges of the new tire 5 Install the tire on the rim mind the direction of rotation 6 Inflate to let the tire get its position on the rim...

Page 28: ...TYRES SLICK TYRES COLD 20 WARM WET CONDITIONS Little water slightly drop the pressure from the recommended value Much water increase the pressure from the recommended value 9 Systematically check the...

Page 29: ...the gap between the pads and the disk ADJUSMENTS the adjustment of the gap between the disk and the pads is done with the screw 1 The standard gap is 1 mm 9 The brake system is a key safety item of th...

Page 30: ...catalogue 7 Make sure the maximum level is 2 Repeat operations 3 to 8 until the brake pedal becomes hard NOTE The brake system must be regularly checked level of brake fluid cover of the fluid reserv...

Page 31: ...l as gaskets 1 Protect the break calipers and the brake disk with a dry piece of cloth 2 Spray the whole kart with the cleaning product and let it act for 30 seconds 3 Wipe the frame and the component...

Page 32: ...ikely to propagate when driving Check the fixings of the body work components make sure they are not loose or damaged When replacing a body work component make sure the screws and bolts are put in the...

Page 33: ...brake pedal free to rotate around its axis 5 Is the brake pads gap correct The steering is hard 1 Are the screws of the stub axles tightened with the right torque 2 Is the caster too high The steerin...

Page 34: ...S Stub axle height Caster and camber Parallelism Seat position Height Dist axle Dist fork Masses Axle type ENGINE carburator type Adjusments Gear ratio NOTES 8 10 9 Partial 4 1 Partial 1 Partial 2 Par...

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